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Process, Power & Marine
SmartPlant Process Safety
Ray Howarth
21-22 August 2008
Hilton Opera Hotel
Hanoi, Vietnam
Process, Power & Marine
August 27, 2008 – 2 –
Operating the Plant
Integrate ALL Information ...
DESIGN & PROCESS
Create the SMART PLANT of the Future …
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 3 –
“The process always tells on itself.”
BASF Sr. Staff Engineer.
Cuts through information overload
“It’s not WHATWHAT you know, it’s WHENWHEN you know it!”
FALCONEER Listens …Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 4 –
Smart Plant of the Future - NOW
The Virtual Engineer in the Smart ProcessThe Right Information Automatically Provided at the RightTime
Cost Savings, Increased Production
Improved Daily Workflow
Better, More Timely Decision-Making
Enhanced Safety
BENEFITS & ROI
FALCONEER™ IV - SPPIDFALCONEER™IV Process Performance Solution - MakingPlants Smarter, Safer & More Profitable by Design
SmartPlant Enterprise Bundle for O/O
SmartPlant Enterprise (SPO) for O/O
Smart Link from Control Systems to SAP
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & MarineThe Drivers/Challenges
Support of Plant Strategy
Production, quality, safety, resource utilization
Reduce Operational Risks such as:
Production interruption
Regulatory compliance
Safety Incidents
Knowledgeable Workforce
Reduce Engineering Costs such as:
Turnaround/Outage Planning & Execution
Preventative Maintenance Planning & Execution
Inspections
Reduce operational overhead cost (contractors / own staff)
How to retain knowledge
How to regain knowledge
Making Plants Smarter, Safer &More Profitable By Design
SMART PLANT
PERFECT PLANT
INTELLIGENT PLANT
of the FUTURE
Process, Power & Marine
August 27, 2008 – 6 –
Operation at Design
Operation at Capacity
Instrumentation Calibration
Safety Systems
ISO Systems
Environmental Systems
Design Validation & Operational RiskMaking Plants Smarter, Safer &More Profitable By Design
Process, Power & MarineWhat is FALCONEER™
THE VIRTUAL ENGINEERTHE VIRTUAL ENGINEER
The Right Information AutomaticallyProvided at the Right Time!
Process Performance Auditing &Advising Software
Real-time
Process Information Management
Fundamental Engineering Models-based
Patented-Pending
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 8 –
CONTROL SYSTEM
• Flow
• Temperature
• Pressure
• Level
SHOULD
WORK
IS
WORKING
ADVICEOK ORPROBLEMS
Process Designand OperationInformation
THE MFGPROCESS
System Auditing
Point Auditing
DIGITAL DASHBOARD
• KPI
• CHARTS
• REPORTS
• EMAILS
How Does FALCONEER™ IV Work? Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 9 –
• WHAT HAPPENED SINCE
YESTERDAY?
• CHECK OPERATIONS
•CONTROL ROOM
•SPREADSHEETS
•DCS TOOLS
• PROBLEMS?
•IMMEDIATE ACTION
•ADDITIONALRESOURCES REQUIRED
•LONGER TERM PLAN
•FORM TEAM
•GATHER INFO
•ANALYZE INFO
•ID CAUSE
•DEVELOP SOLUTIONS
•CREATE PROJECT
• DOCUMENT
•PSM
•ISO
•MOC
•OPERATION NORMAL
•PROJECT WORK
•REPORTS
•MEETINGS
•INTERRUPTIONS
•PROCESS PROBLEMS
•PROCESS OPPORTUNITIES
• IMPLEMENT SOLUTION
•FORM TEAM
•DEVELOP PLAN
•INVESTIGATE
•GATHER INFO
•ANALYZE INFO
•IDENTIFY CAUSE
•DEVELOP SOLUTIONS
•PREPARE FOR TOMORROW
at
Improved Daily Workflow &Information Management Making Plants Smarter, Safer &
More Profitable By Design
Process, Power & MarineREAL BENEFITS!!
Global Industry Benchmarks(BASF, FMC, PPG, Taiwan, India)
Prevented unscheduled shutdownsaving >$200,000 per day
Improved Power GenerationRevenue >$200,000 per year
$30,000 Savings with One Alert onSteam System
Steam Reconciliation Savings of$50,000 in 6 months
Raw Material Savings of >$40,000per Quarter
Energy Savings Opportunities> $70,000 per Month w/ Natural Gas
> $100,000 per year Pumps & Blowers
The real value of right information at the right time!
Making Plants Smarter, Safer &More Profitable By Design
A former Foxboro managerappreciates our approach as:“being rigorous enough to
identify the problems without
being too complex or expensive,
combined with being easy
enough to configure and
maintain.”
“Compared to other approaches,
FALCONEER is more
fundamental with easily
configurable and
understandable equations and
logic”, according to FMC
Process, Power & MarineREAL BENEFITS!!
Global Industry Benchmarks(BASF, FMC, PPG, Taiwan, India)
Prevented unscheduled shutdownsaving >$200,000 per day
Improved Power GenerationRevenue >$200,000 per year
$30,000 Savings with One Alert onSteam System
Steam Reconciliation Savings of$50,000 in 6 months
Raw Material Savings of >$40,000per Quarter
Energy Savings Opportunities> $70,000 per Month w/ Natural Gas
> $100,000 per year Pumps & Blowers
Savings per Costof Production
Low(cents /$)
High(cents /$)
Operating CostsReduction
0.1 2.0
Maintenance CostsReduction
0.1 0.5
Improved Efficiencies 0.3 1.0Addl Product Sales 1.0 2.0Reduced Energy Usage 0.1 0.5OVERALL ANNUALCOST SAVINGSPOTENTIAL
1.6 6.0
% UNIT COSTImprovement
1.6% 6.0%
+ IMPROVED SAFETY+ IMPROVED SAFETY
The real value of right information at the right time!
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
FALCONEER
THE FUTURE IS NOW!
FALCONEER IS SAP’S & INTERGRAPH’S DIRECT LINK
TO THE PLANT FLOOR AND CONTROL SYSTEM.
Benefits of adding the FALCONEER business package to your SPO Core solution:
PLANT OPTIMIZATION
ASSISTANT
ENGINEERING ASSISTANT FOR
RELIABILITY
Virtual Engineer
Mass & Energy Balance Engine
Statistical & Model Based Trending
Save Hundreds of Thousands of $$$
Real-time Sensor & Process Validation
Soft & Inferential Sensors for Reliability
Abnormal Condition & Fault Detection
Prevent Downtime, Accidents, Releases
The SmartPlant® Enterprise for Owner Operators (SPO) Operating Plant Solution builds upon the SPO Core Solution and provides business packages such as FALCONEER to support common, critical work processes for the operating plant.
Process, Power & Marine
August 27, 2008 – 13 –
OO Bundle Solution Components
Engineering tasks that made up the solution:SmartPlant P&ID
Rule and asset based intelligent P&ID solutionSmartPlant Process Safety
Knowledgebase HAZOP analysis solutionSmartPlant Isometrics (formerly I-Sketch)
Specification driven Isometric solution
FALCONEER Process PerformanceValidation, Abnormal Condition Detection &Optimization
Functionality Out-of-the-Box capabilities
Flexibility to be configured to meet specific user demands
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 14 –
Design to Operations Business Cases
Add Monitoring System for Compliance
Automating HAZOP Process
Correcting Equipment PerformanceCorrecting Equipment Performance
Support Systems•PID
•Equipment Spec
•Instrument Specs
•Predictive / Preventive Maintenance
•Simulations
•Excel
•Pilot Study Reports
•SOPS
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 15 –
Intelligent
P&ID’s
Existing
P&ID’s
Implement
Project
Develop Solution
1) Design Modification
2) Process Change
DCS
Historian
Data Consolidation
Specifications
Controls
Piping
Other
Correcting PerformanceEquipment or Process Unit
Underperforming
DCS
HistorianID Problem & Root Cause
Validate
Solution
Engineering Models
Spreadsheets,
Simulations
Maintain & Optimize
Improved or Design Performance
Real-Time Performance
Monitoring & Auditing
Safety
check
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 16 –
Cost savings
Cost of the solution for 3 users$95k (incl. training and fewdays of consultancy)
ROI with the first year ofprojects
$113,540 - $95,000= $18,540
plus Cost Avoidance orOpportunity Cost Savingsranging in the hundreds tothousands of dollars per hourthat problem persistsunrecognized
Task Today Smart Plant
Problem Analysis & ID 16 $1,600 2 $200
As-built 40 $2,400 10 $600
Safety Check 100 $6,000 40$2,40
0
Process Validation 125 $7,500 35$2,10
0
Update design 80 $4,800 40$2,40
0
Commissioning 24 $1,440 12 $720
Update documentation 25 $1,500 10 $600
Savings $25,240$9,02
0
*based on estimates
Savings $16,220
Workflow cases per year 7 $113,540
ROI – Correcting Performance Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 17 –
Business Case –Correcting Performance
Benefits
Virtual Engineer - Analyze process performance
Maintain Safe ConditionsOperational Risk Management
Abnormal Condition Detection & Reporting
Fault & Failure Detection & Reporting
Validation of Safety Critical Instrumentation
Provide recommendations to improve output
Ensure design consistency
Provide consistent P&ID updates
Safety checks on the modifications
Ensure P&ID, process data, Isometrics and safety areall consistent and verified.
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 18 –
ROI Recap on 3 Business Cases
Automating HAZOP Process 168,000
Add Monitoring System for Compliance $139,500
Correcting Equipment Performance 113,540
Total ROI $421,040
Less Cost 95,000
Total ROI 1st Year of Projects $326,040
Plus Cost Avoidance or Opportunity Cost Savingsranging in the hundreds to thousands of dollars per
hour that problems persist unrecognized
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 19 –
FALCONEER Case Studies
A former Foxboro manager appreciates our approach as “being
rigorous enough to identify the problems without being toocomplex or expensive, combined with being easy enough toconfigure and maintain.”
Chemical\Petrochemical
•Solid Oxidizer Plant
•EO Plant
•Polymerization Plants
•Incinerators
•Pipelines (Oil & Gas)
•Salt Plant
Water & Waste Water
•Utilities
•Chemicals
•Energy
Power Generation
•Co-Generation
•Boiler Systems
Pulp & Paper
•Pulp Mill
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & MarineCUSTOMER WANTS…
• Process Information (Asset)
Management
• Real-Time Smart Link for Process
Data to SAP to SP Enterprise to User
• Automated Process Performance
Auditing & Advising
• Leveraging Design Information with
Process Information
USER
$$$
Making Plants Smarter, Safer &More Profitable By Design
SAP
SmartPlantEnterprise
Process, Power & Marine
August 27, 2008 – 21 –
Smart Plant of the Future - NOW
FALCONEER Business Package Delivers
Smart Link from Control System to SAP & Intergraph Enterprise
Mass & Energy Balance Engine for optimizing energy utilization, costs,production
Monitor, Report, Trend key performance indicators (KPI) and metrics inreal time
Energy & Raw Material Use & Cost
Instrumentation & Equipment Condition
Production Capacity & Utilization
Receive proactive notifications of under-performing assets before theyimpact the bottom line
Capture, retain & use aging workforce knowledge base
REDUCED OPERATIONAL RISKREDUCED OPERATIONAL RISK
ENSURING OPERATIONS PER DESIGN!ENSURING OPERATIONS PER DESIGN!
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 22 –
INTERGRAPH 2008
Presenter: Dr. Doug Lenz
Q & A
Making Plants Smarter, Safer &More Profitable By Design
www.falconeertech.com
Process, Power & Marine
August 27, 2008 – 23 –
FALCONEER Process Performance Solution
Models Are the Key
Material Balances
Energy Balances
Performance Equations
Soft Sensor Models
Six Sigma Transfer Functions
Heuristics
Empirical Equations / Correlations
Multivariate Statistical Models
PCA Models
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 24 –
Method Of Minimal Evidence Example
Secondary Model (Eliminates Flow1)
SM1 = 0 = Flow2 * cp * (Temp2 – Temp1)
– Flow3 * cp * (Temp3 – Temp1)
Primary Models (Mass and Energy
Balances)
PM1 = 0 = Flow1 + Flow2 – Flow3 – Leaks
PM2 = 0 = Flow1 * cp * Temperature1
+ Flow2 * cp * Temperature2
– Flow3 * cp * Temperature3
– Leaks * cp * Temperatures
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 25 –
Virtual Statistical Process Control (V-SPC)
FIC6725
0
5
10
15
20
25
5/30/02 0:00 6/1/02 0:00 6/3/02 0:00 6/5/02 0:00 6/7/02 0:00 6/9/02 0:00 6/11/02 0:00 6/13/02 0:00
TIME
RE
AL
DA
TA
CURR V
EWMA V
LCL
Y_LCL
Y_UCL
UCL
Controlled Process Variable
Virtual EWMA Chart
Flow meter
D IC 6034
1 .2 5
1 .2 6
1 .2 7
1 .2 8
1 .2 9
1 .3
1 .3 1
1 .3 2
1 .3 3
1 .3 4
1 .3 5
1 /4 /0 2 0 :0 0 1 /6 /0 2 0 :0 0 1 /8 /0 2 0 :00 1 /1 0 /0 2 0:0 0 1 /1 2/ 02 0 :0 0 1 /1 4 /02 0 :0 0 1 /16 /0 2 0 :0 0 1 /1 8/ 02 0 :0 0 1/ 20 /0 2 0 :0 0
TIM E
RE
AL
DA
TA
C U RR V
E W M A V
L C L
Y _ L C L
Y _ U C L
U C L
Controlled Process Variable
Flow Meter
Failure - 12 Hours before TDCAlarm Indication
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 26 –
Why Can’t our DCS / SCADA do this?
DCS/SCADA monitors individual points only – FALCONEER monitors entireprocess and interactions between points as well
Patent Pending Method and SystemAdds “wisdom” or intelligence to the raw information.
Automatic model & rule generation for enhanced cross-checking
High Level Auditing & AdvisingAccounts for ALL Information from Process
More than just Individual High/Low Alarm Limits and Trending
Statistical-based and Model-based Trending
Real-time Continuous vs. Manual or Scheduled
Proactive and Preemptive versus After-The-FactWHAT & WHEN & WHY
Certain Functions Possible (SPC, KPI, HART)Requires Significantly More Time, Effort, Long-Term Support to Configure & Maintain
Older systems may not even be possible
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 27 –
A Powerful Union
The Power of InformationCaptured in SmartPlant P&ID
The Goldmine of Information& Wisdom Provided byFALCONEER ProcessPerformance Auditing
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 28 –
ROI – Automating HAZOP & Beyond
Cost savings
Cost of the solution for 3 users$95k (incl. training and fewdays of consultancy)
ROI with the first year ofprojects
$168,000 - $95,000=$73,000
Task Today Smart Plant
Safety Study 500 $30,000 230 $13,800
Design updates 100 $6,000 40 $2,400
Process Validation 200 $12,000 75 $4,500
Update documentation 75 $4,500 20 $1,200
Isometric updates 75 $4,500 25 $1,500
Commissioning
Savings $57,000 $23,400
*based on estimates
Savings $33,600
Workflow cases peryear 5 $168,000
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 29 –
Business CaseAutomating HAZOP Process & Beyond
Benefits
Increase the plant safety
Reduce risk of production interruption
Execute safety study faster and with consistentapproach
Consistent and auditable study
MOC
Making resource available for operational tasks
Making Plants Smarter, Safer &More Profitable By Design
Process, Power & Marine
August 27, 2008 – 30 –
Engineering & Process DataWorking Together
100
PT
100
FE
100
FY
100
FIC
100
FT
100
PI
FROM V-8
100
V1V1
Measured Calculated Real-time Cost Daily Cost Monthly Cost Yearly Cost
Real-Time PV 305 SCFH 300 SCFH $45 / hr $1,080 $32,400 $394 K
Design PV 325 SCFH
Deviation + 5 SCFH - 20 SCFH
TOTAL Cost $45 / hr $180 / hr $225 / hr $5,400 $162,000 $1.97 M
• Calibration Error Cost $394 K, Underperforming Asset $1.97 M
• Incinerator Performance – Environmental Liability, Gas Consumption
Making Plants Smarter, Safer &More Profitable By Design